Augmented optical waveguide for use in an optical touch sensitive device

ABSTRACT

An optical touch-sensitive device is able to determine the locations of multiple simultaneous touch events. The optical touch-sensitive device includes multiple emitters and detectors coupled with an optical coupler assembly through a waveguide on the surface on the optical-touch sensitive device. Each emitter produces optical beams which propagate in the waveguide via total internal reflection and are received by the detectors. Touch events disturb the optical beams, and are determined based on the disturbances. The waveguide has at least one dead zone on its surface. The dead zone is formed with a cover layer having a top surface and a bottom surface where the bottom surface of the cover layer is directly coupled to the top surface of the waveguide. The cover layer preserves optical beam propagation in the waveguide and makes the dead zone insensitive to touches on the top surface of the cover layer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/194,368, filed Jun. 27, 2016, which is a continuation of U.S.application Ser. No. 13/947,421, filed Jul. 22, 2013, now U.S. Pat. No.9,405,382, which application claims the benefit of U.S. ProvisionalApplication No. 61/674,958, filed on Jul. 24, 2012, and U.S. ProvisionalApplication No. 61/701,141, filed on Sep. 14, 2012, all of which arehereby incorporated by reference in their entirety.

BACKGROUND

1. Field of Art

This invention generally relates to optical touch-sensitive devices,especially an augmented optical waveguide for use in an opticaltouch-sensitive device.

2. Description of the Related Art

Touch-sensitive displays for interacting with computing devices arebecoming more common. A number of different technologies exist forimplementing touch-sensitive displays and other touch-sensitive devices.Examples of these techniques include, for example, resistive touchscreens, surface acoustic wave touch screens, capacitive touch screensand certain types of optical touch screens.

However, many of these approaches currently suffer from drawbacks. Forexample, some technologies may function well for small sized displays,as used in many modern mobile phones, but do not scale well to largerscreen sizes as in displays used with laptop or even desktop computers.Another drawback for some technologies is their inability or difficultyin handling multitouch events. A multitouch event occurs when multipletouch events occur simultaneously. Another drawback is that technologiesmay not be able to meet increasing resolution demands.

Another drawback for some optical touch-sensitive devices is that lightpropagation in optical waveguides in such devices may be altered byattaching materials (e.g., a display) with unknown optical properties tothe optical waveguides. Light typically propagates in such an opticalwaveguide via total internal reflection (TIR). TIR usually requireslight to be trapped in a transmission medium that has a higherrefractive index than its surrounding materials (usually air, with arefractive index of approximately 1). Any object with unknown opticalproperties, or optical properties incompatible with TIR, that is incontact with the optical waveguide will likely reduce the optical energypropagating in the waveguide. This may make measurement of touch-inducedtransmission loss more difficult and lower touch sensing robustness,adversely affecting the touch sensing performance of such an opticaltouch-sensitive device.

Thus, there is a need for augmented optical waveguides for use inoptical touch-sensitive systems.

SUMMARY

An optical touch-sensitive device is able to determine the locations ofmultiple simultaneous touch events. The optical touch-sensitive deviceincludes multiple emitters and detectors coupled with an optical couplerassembly through a waveguide on the surface on the optical-touchsensitive device. Each emitter produces optical beams which propagate inthe waveguide via total internal reflection and are received by thedetectors. Touch events disturb the optical beams, and are determinedbased on the disturbances. The waveguide has at least one dead zone onits surface. The dead zone is formed with a cover layer having a topsurface and a bottom surface where the bottom surface of the cover layeris directly coupled to the top surface of the waveguide. The cover layerpreserves optical beam propagation in the waveguide and makes the deadzone insensitive to touches on the top surface of the cover layer.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the present invention will now be described, by way ofexample, with reference to the accompanying drawings, in which:

FIG. 1 is a diagram of an optical touch-sensitive device, according toone embodiment.

FIG. 2 is a flow diagram for determining the locations of touch events,according to one embodiment.

FIGS. 3A-3B illustrate a frustrated TIR mechanism for a touchinteraction with an optical beam.

FIG. 3C illustrates a touch interaction with an optical beam enhancingtransmission.

FIGS. 4A-4C are top views of differently shaped beam footprints.

FIGS. 5A-5B are top views illustrating active area coverage by emittersand detectors.

FIG. 6 is a side view of an optical touch-sensitive device including aside coupled optical coupler assembly.

FIG. 7 is a side view of an optical touch-sensitive device including anedge coupled optical coupler assembly.

FIGS. 8A-8B are top views of an optical touch-sensitive device includinga side coupled optical coupler assembly and a display module.

FIG. 9 is a perspective view of an optical touch-sensitive deviceincluding a side coupled optical coupler assembly.

FIG. 10A is a side view of an optical touch-sensitive device with an airgap between the display and the waveguide.

FIG. 10B is a side view of an optical touch-sensitive device with anaugmented waveguide.

FIG. 10C is a side view of an optical touch-sensitive device with anaugmented waveguide where optical beams pass through the intermediatelayer to reach the emitters/detectors.

FIG. 11A is a top view of an optical touch-sensitive device with a frameusing an infrared (IR) ink layer.

FIG. 11B is a side view of an optical touch-sensitive device with aframe using an IR ink layer.

FIGS. 12A-12C are side views of an optical touch-sensitive deviceillustrating a frame made with an IR ink layer and a dark ink layer.

FIG. 13 is a side view of an optical touch-sensitive device illustratinga frame made with an IR black optical coupler and a dark ink layer.

FIG. 14 is a side view of an optical touch-sensitive device illustratingdead zones.

FIG. 15A is a top view of an optical touch-sensitive device illustratinga fixed graphics zone.

FIG. 15B is a side view of an optical touch-sensitive deviceillustrating a fixed graphics zone.

FIG. 16 illustrates the sequence of steps to manufacture an opticaltouch-sensitive device with a frame using an IR ink layer and a dark inklayer.

FIG. 17 illustrates the sequence of steps to manufacture an opticaltouch-sensitive device with a frame using an IR black optical couplerand a dark ink layer.

DETAILED DESCRIPTION

I. Introduction

A. Device Overview

FIG. 1 is a diagram of an optical touch-sensitive device 100, accordingto one embodiment. The optical touch-sensitive device 100 includes acontroller 110, emitter/detector drive circuits 120, and atouch-sensitive surface assembly 130. The surface assembly 130 includesan active area 131 over which touch events are to be detected. Forconvenience, the active area 131 may sometimes be referred to as theactive surface or surface, as the active area itself may be an entirelypassive structure such as an optical waveguide. The assembly 130 alsoincludes emitters and detectors arranged along the periphery of theactive area 131. In this example, there are J emitters labeled as Ea-EJand K detectors labeled as D1-DK. The device also includes a touch eventprocessor 140, which may be implemented as part of the controller 110 orseparately as shown in FIG. 1. A standardized API may be used tocommunicate with the touch event processor 140, for example between thetouch event processor 140 and controller 110, or between the touch eventprocessor 140 and other devices connected to the touch event processor.

The emitter/detector drive circuits 120 serve as an interface betweenthe controller 110 and the emitters Ej and detectors Dk. The emittersproduce optical “beams” which are received by the detectors. Preferably,the light produced by one emitter is received by more than one detector,and each detector receives light from more than one emitter. Forconvenience, “beam” will refer to the light from one emitter to onedetector, even though it may be part of a large fan of light that goesto many detectors rather than a separate beam. The beam from emitter Ejto detector Dk will be referred to as beam jk. FIG. 1 expressly labelsbeams a1, a2, a3, e1 and eK as examples. Touches within the active area131 will disturb certain beams, thus changing what is received at thedetectors Dk. Data about these changes is communicated to the touchevent processor 140, which analyzes the data to determine thelocation(s) (and times) of touch events on surface 131.

B. Process Overview

FIG. 2 is a flow diagram for determining the locations of touch events,according to one embodiment. This process will be illustrated using thedevice of FIG. 1. The process 200 is roughly divided into two phases,which will be referred to as a physical phase 210 and a processing phase220. Conceptually, the dividing line between the two phases is a set oftransmission coefficients Tjk.

The transmission coefficient Tjk is the transmittance of the opticalbeam from emitter j to detector k, compared to what would have beentransmitted if there was no touch event interacting with the opticalbeam.

The use of this specific measure is purely an example. Other measurescan be used. In particular, since we are most interested in interruptedbeams, an inverse measure such as (1−Tjk) may be used since it isnormally 0. Other examples include measures of absorption, attenuation,reflection or scattering. In addition, although FIG. 2 is explainedusing Tjk as the dividing line between the physical phase 210 and theprocessing phase 220, it is not required that Tjk be expresslycalculated. Nor is a clear division between the physical phase 210 andprocessing phase 220 required.

Returning to FIG. 2, the physical phase 210 is the process ofdetermining the Tjk from the physical setup. The processing phase 220determines the touch events from the Tjk. The model shown in FIG. 2 isconceptually useful because it somewhat separates the physical setup andunderlying physical mechanisms from the subsequent processing.

For example, the physical phase 210 produces transmission coefficientsTjk. Many different physical designs for the touch-sensitive surfaceassembly 130 are possible, and different design tradeoffs will beconsidered depending on the end application. For example, the emittersand detectors may be narrower or wider, narrower angle or wider angle,various wavelengths, various powers, coherent or not, etc. As anotherexample, different types of multiplexing may be used to allow beams frommultiple emitters to be received by each detector.

The interior of block 210 shows one possible implementation of process200. In this example, emitters transmit 212 beams to multiple detectors.Some of the beams travelling across the touch-sensitive surface aredisturbed by touch events. The detectors receive 214 the beams from theemitters in a multiplexed optical form. The received beams arede-multiplexed 216 to distinguish individual beams jk from each other.Transmission coefficients Tjk for each individual beam jk are thendetermined 218.

The processing phase 220 can also be implemented in many different ways.Candidate touch points, line imaging, location interpolation, touchevent templates and multi-pass approaches are all examples of techniquesthat may be used as part of the processing phase 220.

II. Physical Set-up

The touch-sensitive device 100 may be implemented in a number ofdifferent ways. The following are some examples of design variations.

A. Electronics

With respect to electronic aspects, note that FIG. 1 is exemplary andfunctional in nature. Functions from different boxes in FIG. 1 can beimplemented together in the same component.

B. Touch Interactions

Different mechanisms for a touch interaction with an optical beam can beused. One example is frustrated total internal reflection (TIR). Infrustrated TIR, an optical beam is confined to an optical waveguide bytotal internal reflection and the touch interaction disturbs the totalinternal reflection in some manner. FIGS. 3A-3B illustrate a frustratedTIR mechanism for a touch interaction with an optical beam 302.

The touch interactions can also be direct or indirect. In a directinteraction, the touching object 304 (e.g., a finger or stylus) is theobject that interacts with the optical beam 302. For example, a fingermay have a higher index of refraction than air, thus frustrating TIRwhen the finger comes into direct contact with a top surface 306 of thewaveguide. In an indirect interaction, the touching object interactswith an intermediate object, which interacts with the optical beam. Forexample, the finger may cause a high index object to come into contactwith the waveguide, which may cause a change in the index of refractionof the surrounding materials of the waveguide.

Note that some types of touch interactions can be used to measurecontact pressure or touch velocity, in addition to the presence oftouches. Also note that some touch mechanisms may enhance transmission,instead of or in addition to reducing transmission. FIG. 3C illustratesa touch interaction with an optical beam enhancing transmission. Forsimplicity, in the remainder of this description, the touch mechanismwill be assumed to be primarily of a blocking nature, meaning that abeam from an emitter to a detector will be partially or fully blocked byan intervening touch event. This is not required, but it is convenientto illustrate various concepts.

For convenience, the touch interaction mechanism may sometimes beclassified as either binary or analog. A binary interaction is one thatbasically has two possible responses as a function of the touch.Examples include non-blocking and fully blocking, or non-blocking and10%+ attenuation, or not frustrated and frustrated TIR. An analoginteraction is one that has a “grayscale” response to the touch:non-blocking passing continuously or in a gradated or stepped mannerfrom partially blocking to blocking.

C. Emitters, Detectors and Couplers

Each emitter transmits light to a number of detectors. Usually, eachemitter outputs light to more than one detector simultaneously.Similarly, each detector receives light from a number of differentemitters. The optical beams may be visible, infrared (IR) and/orultraviolet (UV) light. The term “light” is meant to include all ofthese wavelengths and terms such as “optical” are to be interpretedaccordingly. The wavelength range of interest encompasses a largespectrum, including but not limited to a range from 200 nm to 2000 nm,or any sub-range therein including, for example, 800 nm to 980 nm.

Examples of the optical sources for the emitters include light emittingdiodes (LEDs) and semiconductor lasers. IR sources can also be used.Modulation of the optical beams can be external or internal. Examples ofsensor elements for the detector include charge coupled devices,photodiodes, photoresistors, phototransistors, and nonlinear all-opticaldetectors.

The emitters and detectors may also include optics and/or electronics inaddition to the main optical source and sensor element. For example,emitters and detectors may incorporate or be attached to lenses tospread and/or collimate emitted or incident light. Additionally, one ormore optical coupling assemblies (couplers) of varying design can beused to couple the emitters and detectors to the waveguide. Thewaveguide, coupler, and any intervening optical elements all have asimilar refractive index that is higher than that of air to facilitateTIR throughout the entire optical path of each beam. These elements maybe physically coupled together using a bonding agent that has a similarrefractive index to the waveguide and coupler. Alternatively, at variouspoints along the optical path air gaps may be present between elementsin place of a bonding agent.

D. Optical Beam Paths

FIGS. 4A-4C are top or side views of differently shaped beam footprints.Another aspect of a touch-sensitive system is the shape and location ofthe optical beams and beam paths. In FIG. 1, the optical beams are shownas lines. These lines should be interpreted as representative of thebeams, but the beams themselves may be different shapes and footprints.A point emitter and point detector produce a narrow “pencil” beam with aline-like footprint. A point emitter and wide detector (or vice versa)produce a fan-shaped beam with a triangular footprint. A wide emitterand wide detector produce a “rectangular” beam with a rectangularfootprint of fairly constant width. Depending on the width of thefootprint, the transmission coefficient Tjk behaves as a binary or as ananalog quantity. It is binary if the transmission coefficienttransitions fairly abruptly from one extreme value to the other extremevalue as a touch point passes through the beam. For example, if the beamis very narrow, it will either be fully blocked or fully unblocked. Ifthe beam is wide, it may be partially blocked as the touch point passesthrough the beam, leading to a more analog behavior.

Beams may have footprints in both the lateral (horizontal) direction, aswell as in the vertical direction. The lateral footprint of a beam maybe the same or different from the horizontal footprint of a beam.

The direction and spread of the light emitted from the emitters andreceived by the detectors may vary in spread or angle from beamfootprints intended to cover the active area 131. To shape the beams toachieve the intended footprints, lenses may be attached to the emittersand detectors. For example, point emitters and detectors may be used inconjunction with lenses to spread beams in the horizontal or verticaldirections.

FIGS. 5A-5B are top views illustrating active area coverage by emittersand detectors. As above, the emitters and detectors are arranged alongthe periphery of the active area. All the emitters may be arranged ontwo sides of the active area, for example two adjacent perpendicularsides as illustrated in FIG. 5A. Similarly, all of detectors may bearranged on the other two sides of the active area. Alternatively, theemitters and detectors may be mixed or interleaved according to apattern as illustrated in FIG. 5B. This pattern may be one emitter inbetween each detector, or another more complicated arrangement.

In most implementations, each emitter and each detector will supportmultiple beam paths, although there may not be a beam from each emitterto every detector. The aggregate of the footprints from all beams fromone emitter will be referred to as that emitter's coverage area. Thecoverage areas for all emitters can be aggregated to obtain the overallcoverage for the system.

The footprints of individual beams can be described using differentquantities: spatial extent (i.e., width), angular extent (i.e., radiantangle for emitters, acceptance angle for detectors) and footprint shape.An individual beam path from one emitter to one detector can bedescribed by the emitter's width, the detector's width and/or the anglesand shape defining the beam path between the two. An emitter's coveragearea can be described by the emitter's width, the aggregate width of therelevant detectors and/or the angles and shape defining the aggregate ofthe beam paths from the emitter. Note that the individual footprints mayoverlap. The ratio of (the sum of an emitter's footprints)/(emitter'scover area) is one measure of the amount of overlap.

The overall coverage area for all emitters should cover the entirety ofthe active area 131. However, not all points within the active area 131will be covered equally. Some points may be traversed by many beam pathswhile other points traversed by far fewer. The distribution of beampaths over the active area 131 may be characterized by calculating howmany beam paths traverse different (x,y) points within the active area.The orientation of beam paths is another aspect of the distribution. An(x,y) point that is derived from three beam paths that are all runningroughly in the same direction usually will be a weaker distribution thana point that is traversed by three beam paths that all run at 60 degreeangles to each other.

The concepts described above for emitters also apply to detectors. Adetector's coverage area is the aggregate of all footprints for beamsreceived by the detector.

III. Optical Coupler Assemblies and Related Hardware

A. General Description

FIGS. 6 and 7 are side views of an optical touch-sensitive deviceincluding a side 602 and an edge 702 coupled optical coupler assembly,respectively. As introduced above, the optical touch-sensitive device600, 700 includes a planar optical waveguide 604 that is opticallycoupled to the emitters and detectors 606 with an optical couplerassembly (or coupler) 602 or 702. The optical touch-sensitive device600, 700 may also include any one or more of a printed circuit board(PCB) 608, an ambient light shield 610, an IR transmissive layer 612,one or more air gaps 636 and associated ambient light absorbing surfaces614, and a display module 616. The ambient light shield 610 may be madeof a light reflective material or a light absorbing material.

The waveguide 604 extends past the lateral edge of the display module.The waveguide may be constructed of a material that is rigid orflexible. In one embodiment, the waveguide includes a single plane ofmaterial. Regardless of the type of material used to construct thewaveguide, the waveguide has a top surface that is substantially orexactly parallel to its bottom surface. The top surface of the waveguideis oriented to receive touch input. The bottom or side edge surface ofthe waveguide, depending upon the implementation, is optically coupledto the coupler outside the lateral extent of the display module (e.g.,the viewing area of the display). As described above, optical beamstravel through the waveguide using TIR. That is, optical beams reflectoff of the top and bottom surfaces of the waveguide at angles greaterthan a critical angle from the normal to the top and bottom surfaces ofthe waveguide. Touch events, detected using frustrated TIR, are receivedwithin an active area 131 of the top surface of the waveguide.

The coupler may be side coupled 602, as illustrated in FIG. 6, or edgecoupled 702, as illustrated in FIG. 7, to the waveguide. For both theside coupled and edge coupled cases, the coupler may also be configuredto reorient beams to accommodate any orientation of emitters anddetectors with respect to the waveguide. The coupler may also beconfigured to translate beams laterally or vertically to accommodate anyposition of emitters and detectors. The coupler, and touch-sensitivedevice more generally, are also configured to prevent or reduce ambientlight entering the waveguide from hitting the emitters and detectors.

The coupler may be formed with a single piece of material, or withseveral optically coupled pieces. Each emitter and detector 606 may haveits own coupler to couple light into and out of the waveguide.Alternatively, emitters and/or detectors may share a coupler. Thecoupler may be made with any number of materials including, for example,glass or plastic.

The emitters and detectors 606 are arranged beneath the bottom surfaceof the waveguide along the periphery of the display module. Positioningthe emitters and detectors along the periphery of the display moduleincludes positioning the emitters and detectors outside the outer sideedge of the display module, so that the emitters and detectors are tothe side, laterally, around the display module. Positioning the emittersand detectors along the periphery of the display module also includespositioning the emitters and detectors underneath the bottom side of thedisplay module near the side edge of the display module. The emittersand detectors are electrically coupled to the PCB 608 which may includeor electrically couple to the emitter/detector drive circuits 120.

The optical touch-sensitive device is configured to operate inconjunction with a display (or screen) module 616 configured to displayimages, however the display module is not necessarily part of theoptical touch sensitive device. The display module is illustrated forclarity. The drawings of the device in FIGS. 6-7 are not to scale, andit is expected that the display module 616 and active area 131 will inpractice be much larger than the coupler and related hardware.

B. Side Coupled Optical Couplers

FIG. 6 is a side view of an optical touch-sensitive device 600 includinga side coupled optical coupler assembly 602. In device 600, thedetectors and emitters 606 are oriented to receive and emit light,respectively, in a direction parallel to the top and bottom surfaces ofthe waveguide 604, such that light exits the emitters and enters thedetectors in substantially the same lateral direction it travelslaterally through the waveguide 604.

The coupler 602 is side coupled to the bottom surface of the waveguide604. Generally, the side coupling consists of a single planar couplingsurface 630 on the top surface of the coupler 602 that is opticallycoupled, directly or indirectly, to the bottom surface of the waveguide604. Although as illustrated the coupling surface 630 is the entirety ofone surface of the coupler 602, this need not be the case.

C. Edge Coupled Optical Couplers

FIG. 7 is a side view of an optical touch-sensitive device 700 includingan edge coupled optical coupler assembly 702. In coupler 702, thedetectors and emitters 606 are oriented to receive and emit light,respectively, in a direction perpendicular to the top and bottomsurfaces of the waveguide 604, such that light exits the emitter in adirection rotated by ninety degrees with respect to the direction ittravels laterally through the waveguide 604.

The coupler 702 is edge coupled to a side edge surface of the waveguide604. Generally, the edge coupling consists of a single planar couplingsurface 730 on a side edge surface of the coupler 702 that is opticallycoupled, directly or indirectly, to the side edge of the waveguide 604.The coupler 702 may include a reflective surface 722 and a clean orreflective surface 724.

D. Display and Associated Hardware

FIGS. 8A-8B are top views of an optical touch-sensitive device includinga side coupled optical coupler assembly and a display module. The topview illustrates the relative lateral extents of the waveguide 804, thedisplay module 816, and the active area 131. In this example, thewaveguide 804 extends laterally past and covering the display module816, couplers 802 including the coupling surface 830, andemitters/detectors 806. From top down, a portion of the coupler is thecoupling surface 830, and another portion is covered by the light shield810.

FIG. 8A illustrates an implementation where relatively few couplers 802(in this case four) are each shared between a number of emitters and/ordetectors 806. FIG. 8B illustrates an implementation where eachemitter/detector 806 has its own coupler 802. In another implementation,a single coupler may be shared between all emitters and detectors (notshown).

FIG. 9 is a perspective view of an optical touch-sensitive device 900including a side coupled optical coupler assembly. In this example, thecouplers 902 are positioned below the bottom surface of the waveguide904 and also near the edges of the waveguide to leave room for a displayin the middle of the touch-sensitive device. Light is injected intoand/or extracted from the waveguide 904 at the coupling surface 930. Inone implementation, the coupling surface 930 is attached to thewaveguide 904 via optically clear adhesive (OCA). Alternatively, othermethods that enable a good transfer of light energy between the couplers902 and the waveguide 904 may be used. The OCA binding the couplers tothe waveguide may not be explicitly shown in all figures. Typically, OCAis transparent to visible light and/or optical beams propagating in thewaveguide.

In one approach, an OCA layer (either in liquid form or in the form of atape adhesive) is attached to the waveguide 904 first, and the couplers902 are attached to the waveguide via the OCA layer. Alternatively, anOCA layer may be attached to each coupler first, and the OCA-coveredcouplers are then attached to the waveguide. A fixture may be used forguidance to precisely place and attach the couplers to the waveguide.

IV. Intermediate Layer

A. General Description

An intermediate layer may be used to augment the waveguide of theoptical touch sensitive device. In most cases, the intermediate layerhelps preserve light propagation in the waveguide. This is useful, forexample, when the waveguide, particularly the side opposite to thesurface intended to receive touch events (e.g., the bottom surface), isattached to another object with unknown optical properties, or opticalproperties that are incompatible with TIR (e.g., the object has a higherrefractive index than that of the waveguide). Generally, the attachedobject is affixed in continuous contact with the waveguide in amanufactured touch sensitive device. The attached object may be adisplay, a non-display surface, a transparent structure, anon-transparent structure, a thin film (transparent or not), and/or acoating (e.g., a thin layer of compound).

Alteration of the interface between the waveguide and its surroundingmedium is generally undesirable. In total internal reflection, light istrapped in a transmission medium (e.g., the waveguide) having a higherrefractive index (RI) than the surrounding medium (usually air, with arefractive index of approximately 1). As a result, any object touchingthe waveguide may potentially reduce the optical energy propagating inthe waveguide if the object has optical properties that are incompatiblewith TIR. This may adversely affect the touch-sensitive device's touchsensing performance. For example, reduced optical energy in thewaveguide may make measurement of touch-induced transmission loss moredifficult, which lowers touch sensing robustness.

Augmenting the waveguide with an intermediate layer significantlyreduces the abovementioned negative impacts of the attached object.Generally, the waveguide is augmented by interposing an intermediatelayer between the waveguide and the attached object. The intermediatelayer not only provides a desired mechanical binding function, but alsomodifies the waveguide interface with known and controlled opticalproperties of the intermediate layer.

In one embodiment, the intermediate layer has a refractive index smallerthan the refractive index of the waveguide. In this embodiment, theintermediate layer is said to be constructed of a low-RI material, andmay also be referred to as a low-RI layer. The low RI layer preservesoptical beam propagation in the waveguide via TIR. In anotherembodiment, the intermediate layer is a mirror or includes a mirroredsurface for optical beams propagating in the waveguide, and optical beampropagation in the waveguide is preserved via specular reflection. Inthis embodiment, the intermediate layer is also referred to as a mirrorlayer. The mirror layer may be configured to be reflective of theoptical beams propagating in the waveguide, but transparent to visiblelight.

B. Attachment and Mechanism of Operation

FIG. 10A is a side view of an optical touch-sensitive device with an airgap between the display and the waveguide. In this example, PCBs 1008 aand 1008 b are directly attached to couplers 1002 a and 1002 b,respectively. The emitters and detectors (not shown) are electricallycoupled to the PCBs which may include or electrically couple to theemitter/detector drive circuits 120. The position and orientation of theemitters and detectors relative to the couplers are designed to have ahigh amount of light transfer between them. In an alternate embodiment,the PCBs are not directly attached to the couplers, but indirectly via,for example, a device chassis (not shown). Illustratively, an opticalbeam is shown that is generated from an emitter connected to the PCB1008 a. The beam then propagates through coupler 1002 a, enters thewaveguide 1004 through the coupling surface 1030 a, propagates in thewaveguide 1004 via TIR, exits the waveguide 1004 and enters the coupler1002 b through the coupling surface 1030 b, propagates through thecoupler 1002 b, and finally reaches a detector connected to the PCB 1008b. To avoid interfering with the visible images from the display, theoptical beams propagating in the waveguide typically have near IRwavelengths ranging from 800 nm to 980 nm. Other wavelengths are alsopossible.

A display module 1016 is positioned in between the couplers 1002 a and1002 b, but does not directly touch the waveguide. That is, there is anair gap between the waveguide and the display module. The waveguide 1004shown in FIG. 10A is therefore not augmented as there is no intermediatelayer.

There are several possible reasons to augment the waveguide. As shown inFIG. 10A, the waveguide may function as a thin protective layer of coverglass for the display module. This thin layer of cover glass may beeasily broken due to for example mechanical shocks. Laminating thewaveguide to the display makes the touch-sensitive device more robust tomechanical shocks. Parallax may also be reduced thanks to the laminationbecause the distance between the display and the waveguide is reduced(e.g., no air gap). Further, laminating the waveguide to the display canprevent significant deflection of the waveguide when touched from thetop, thus avoiding a situation where the waveguide may physicallycontact the display and alter image quality.

FIG. 10B is a side view of an optical touch-sensitive device 1000 withan augmented waveguide. The augmented waveguide 1004 is shown with anintermediate layer 1050 attached to its bottom. The display module 1016is to be attached to the waveguide, as shown by an arrow. In thisexample, a thin layer of OCA 1040 is attached to the display topsurface. The OCA layer 1040 may be in the form of a film or resin whichcan be cured by exposure to UV, heat, humidity, or a combination ofthem. The OCA layer 1040 attaches the display module 1016 to theintermediate layer 1050 at the bottom surface of the waveguide 1004.Both the OCA layer 1040 and the intermediate layer 1050 are transparentto visible light to allow images on the display to be viewed through thewaveguide.

In one embodiment, the OCA layer may function as the intermediate layer,thereby waiving the need of having a separate intermediate layer. Forexample, the OCA layer may have a smaller refractive index than that ofthe waveguide. In this case, the OCA layer functions both as anintermediate layer and a mechanical binding layer.

The intermediate layer 1050 extends across the waveguide at least tocover the surface of the display module 1016, but not necessarilyextending to or beyond the couplers 1002. Generally, light passes fromthe coupler to the waveguide without interacting with the intermediatelayer as the lateral extent of the intermediate layer 1050 is limited soas not to cover the border of the waveguide. To achieve this, theoptical touch-sensitive device 1000 is manufactured using a maskinglayer to cover the border of the touch-sensitive device. The maskinglayer may be applied to the bottom surface of the waveguide prior todeposition of the intermediate layer 1050. After the deposition of theintermediate layer is completed, the masking layer can be removed,leaving a frame of clear glass on the bottom surface of the waveguide.In one approach, the couplers 1002 are positioned on the border andattached to the clear glass frame via OCA, with no intermediate layer inbetween.

FIG. 10C is a side view of an optical touch-sensitive device with anaugmented waveguide where optical beams pass through the intermediatelayer to reach the emitters/detectors. In this example, the intermediatelayer 1050 is composed of a low-RI material that is transparent to theoptical beams propagating in the waveguide. The coupler 1002 is made upof several coupler parts 1002-1, 1002-2, and 1002-3. The coupler parts1002-1 and 1002-2 are optically coupled to the waveguide 1004. In somecases, the coupler parts 1002-1 and 1002-2 may be formed as part of thewaveguide 1004 by moulding the waveguide 1004 with the illustratedprofile. This provides a mechanism by which light enters the waveguide1004 at an angle greater than the critical angle between the waveguideand its surrounding air and is trapped within the waveguide 1004 viaTIR. A third coupler part 1002-3 may also be optically coupled(optionally with an air gap) to the intermediate layer 1050 directslight between an emitter/detector 1006 and the intermediate layer 1050.In some cases, the third coupler part 1002-3 may be index matched to theintermediate layer 1050 to facilitate propagation of light between thedetector/emitter 1006 and the intermediate layer 1050, although this isnot required. In this embodiment, the coupler 1002 includes severalindividual coupler parts so that the overall height of the coupler 1002may be minimized. The intermediate layer interposed between the couplerparts 1002-1/1002-2 and the coupler part 1002-3 does not totallyinternally reflect optical beams from the waveguide because theincidence angles at the interfaces 1005 a and 1005 b are less than thecritical angle required for TIR. As shown in FIG. 10C, the intermediatelayer 1050 extends beyond the coupler 1002 to cover the border of thewaveguide 1004. This may simplify manufacturing of the opticaltouch-sensitive device by, for example, waiving the need of using amasking layer to cover the border of the waveguide.

The intermediate layer may be deposited at any stage prior to attachingthe display module provided that the application process of theintermediate layer does not have any negative impact on any other devicecomponents. For example, a high-temperature lamination process may causewarping of optical elements that have already been attached to thewaveguide. Another example of such a negative impact is delamination oflayers that have already been attached to the waveguide. Delaminationcan be avoided by matching the surface energies of adjacent layers. Thesurface energy of a material is a measure of the energy available in themolecules on the surface of the material relative to the energyavailable in the molecules in the bulk of the material. The surfaceenergy of a material is an important contributor to the ease of bondingto other materials. Unmatched surface energies between materialssuggests that the materials are unlikely to be readily bonded. Matchingof surface energies can be achieved by altering functional groups atadjacent surfaces by chemical treatment prior to attaching the adjacentlayers. Functional groups are those parts of a molecule that areinvolved in chemical reactions and form bonds with other materials. Thisterm is especially useful when referring to organic substances. Adhesionof the adjacent layers can also be promoted by altering the topology ofthe adjacent surfaces to cause at least one of two adjacent surfaces tobe rough, thus increasing friction and the surface area available for anadhesive to bind the two adjacent layers.

In one embodiment, the couplers are attached to the waveguide first.Then the display module and the waveguide are laminated together with anintermediate layer also acting as a bonding layer. For example, this canbe achieved by dispensing a liquid low-RI layer onto the waveguide,which will then be brought into contact with the display module. Theliquid low-RI layer is then cured by UV exposure. In this example,accurate dispensing of a predefined volume of low-RI material in apredefined pattern on the waveguide can result in controlled spreadingof the low-RI layer when brought into contact with the display module.Depending on the design, the low-RI material may or may not spread to bein contact with the couplers.

B.1 Low-RI Layer

In one embodiment, the intermediate layer 1050 is made of a materialhaving a refractive index smaller than the refractive index of thewaveguide. In an implementation using a low-RI layer, the low-RI layercan possess a range of refractive index values ranging from as low asair/vacuum (n=1) up to the refractive index of the waveguide materialitself. With a refractive index in this range, the low-RI layersatisfies the condition of total internal reflection for light incidenton the interface between the waveguide and the low-RI layer (e.g., thebottom surface of the waveguide).

A low-RI layer may include a fluoropolymer material or other halogenatedmaterials, which may come from a vapor, liquid, or solid-state sourceand may be applied to the waveguide using an appropriate applicationprocess. For vapor phase low-RI layers, application processes includechemical vapor deposition, plasma deposition, and the like. Liquid phaselow-RI layers can be applied by spin-coating, dip-coating,spray-coating, blade-coating methods, etc. Printing techniques such asscreen printing may also be used to deposit liquid phase low-RI layers.Vapor and liquid phase low-RI layers are often curable by exposure toUV, heat, humidity, electron beams, or a combination of these.

Solid phase low RI-layers (e.g., fluoropolymer films) can be appliedusing a lamination process where the solid phase low-RI layer and/or thewaveguide is brought close to or above a glass transition temperature ofthe low-RI layer and lamination is achieved without the use of anyadhesive. Alternatively, lamination may be achieved via the use of anadhesive (e.g., OCA).

The average (or effective) refractive index of a low-RI layer may beengineered to an appropriate value by the introduction of micro- and/ornano-porosity into the low-RI layer. In this case, the low-RI layer iscomposed of such “porous” materials including hydrogels, xerogels,aerogels, nanofoams, etc. In one approach, such a low-RI layer may bedeposited by oblique angle vacuum deposition, where materials such assilica can be formed into highly nano-porous layers of isolated columnarstructures.

In most cases, the thickness of a low-RI layer is greater than at leasta penetration depth of the evanescent light field in the waveguide. Alow-RI layer of at least this thickness is chosen so that lightpropagating in the waveguide is substantially not influenced by anyadjacent layer to the low-RI layer (e.g. the OCA layer 1040 which isadjacent to the intermediate layer 1050). Alternatively, a low-RI layerof thickness smaller than the penetration depth may also be used,provided that the adjacent layer to the low-RI layer has opticalproperties which preserve TIR and avoid excessive attenuation of lightpropagating in the waveguide.

B.2 Mirror Layer

In an alternate embodiment, light propagation in the waveguide ispreserved via specular reflection at the interface between theintermediate layer and the waveguide. In this case, the intermediatelayer is a mirror layer for optical beams propagating in the waveguideand the optical beams have wavelengths within a narrow range of IRwavelengths (e.g., a narrow band within 800 nm-980 nm). Thus, the mirrorlayer is a narrow band reflector for that narrow range of IRwavelengths. In one implementation, such a narrow band reflector is athin film interference filter (e.g., a dichroic filter) which stronglyreflects light with wavelengths within the narrow range. In anotherimplementation, the narrow band reflector is a holographic film. Aholographic film is made by changing the refractive index of a materialin proportion to the intensity of the holographic interference patternused to expose the holographic film. The holographic interferencepattern is designed in such a way as to produce a total specularreflection for light with wavelengths within the narrow range of IRwavelengths, while being essentially transparent to visible light. Inthis example, the emitters in the optical touch-sensitive device arenarrow band LEDs, or lasers having wavelengths compatible with theholographic film properties.

C. Frame

The optical touch-sensitive device may include a frame for indicatingcertain attributes of the device, such as clearly demarcating the borderof the display and/or separation between zones of the display. Such aframe may be attached to the top or bottom surface of the waveguide.Generally, the frame is opaque to visible light, and may be createdusing an ink layer (e.g., an IR ink layer and/or a dark ink layer),another material such as a colored layer (e.g., a sticker, a pigmentedthin film, etc.), and/or using a coupler that itself is opaque tovisible light. The following description describes an ink implementationof a frame, however other materials are expected to be constructed andfunction similarly. The IR ink is a semi-transparent ink that istransparent in at least part of the near IR wavelength range, forexample from 800 nm to 980 nm, while absorbing or reflecting lightoutside that range including, for example, generally all visible light.Thus, when viewed by a user, the IR ink appears opaque. The dark ink isgenerally opaque to both visible light as well as the IR light used todetect touch events. Despite generally blocking all visible light,either type of ink layer may have a uniform visible color (e.g., black,white, red, blue, green, etc.), or a varying color pattern. The dark inklayer is not necessarily fully opaque, and may include ink layers of anypossible color. As described above, the intermediate layer is typicallytransparent to visible light, however this is not required.

In one embodiment, a bottom frame is constructed by interposing anintermediate layer between the bottom surface of the waveguide and an IRink layer. FIG. 11A is a top view of an optical touch-sensitive device1100 with a bottom frame using an IR ink layer, and FIG. 11B is a sideview of the same device 1100. In this example, the optical beamspropagating in the waveguide are assumed to have near IR wavelengths. Anintermediate layer 1150 is applied to the central portion of thewaveguide bottom surface. An IR ink layer 1160 is applied to the borderof the waveguide bottom surface.

In one embodiment, the IR ink layer 1160 extends from the waveguide edgeand abuts the intermediate layer 1150 (not shown). In another embodimentas shown in FIGS. 11A-11B, the IR ink layer 1160 extends from thewaveguide edge past the boundary of the intermediate layer 1150, andthus overlaps part of the intermediate layer 1150. In the exampleembodiment of FIGS. 11A and 11B, couplers 1102 are optically coupled tothe waveguide at the coupling surface 1130 through the IR ink layer1160. This forms a part of the exterior portion of the frame notoverlapping with the intermediate layer 1150. As a result, light isinjected/extracted with limited attenuation from the IR ink layer andwithout any influence from the intermediate layer. The interior portionof the frame overlapping the intermediate layer does not affect lightpropagation inside the waveguide because the intermediate layer blockslight from interacting with the overlapping IR ink layer. The interiorand exterior portions of the frame may also be referred to as differentframe zones. In the example of FIG. 11, the frame as a whole includesboth the interior and exterior portions. In this example, thedistinction is merely for convenience, as the interior and exteriorportions are merely different portions of the same IR ink layer 1160.However, this is useful in the below-described embodiments where theframe includes more than one material. Other frame zones may also becreated beyond interior and exterior, for example as described furtherbelow with respect to dead zones and fixed graphics.

Attaching a bottom frame to the waveguide maintains the flush aspect ofthe waveguide top surface which functions as the touch screen. The flushnature of the touch screen improves user interaction comfort in thatusers can move their fingers all over the touch screen withoutperceiving any level change. This is usually accomplished by leaving thewaveguide top surface essentially unmodified, with the possibleexception of applied anti-glare coatings, anti-fingerprint coatings,hardenings, etc.

FIGS. 12A-12C are side views of an optical touch-sensitive deviceillustrating a frame made with an IR ink layer and a dark ink layer. InFIG. 12A, the IR ink layer 1260 extends from the edge of the waveguideand abuts the intermediate layer 1250 without any overlap. The coupler1202 is attached to the exterior frame zone. A layer of dark ink 1270covers the remaining bottom surface of the IR ink layer 1260 that is notcovered by the coupler 1202. The dark ink layer 1270 also overlaps aportion of the intermediate layer 1250 to create the interior framezone. The dark ink layer is advantageous because it more fully blockslight relative to the IR ink layer. The dark ink layer does not interactwith optical beams propagating in the waveguide, since it is eitheroutside the optical beam propagation path (e.g., the dark ink layer 1270a) or shielded from the optical beams by the intermediate layer (e.g.,the dark ink layer 1270 b).

FIG. 12B shows another embodiment where the IR ink layer 1260 extends tooverlap with the intermediate layer 1250. The coupler 1202 is attachedto the exterior frame zone. The dark ink layer 1270 is applied to coverthe remaining bottom surface of the IR ink layer 1260 that is notcovered by the coupler 1202, including the interior frame zone where theIR ink layer overlaps with the intermediate layer. The dark ink layer1270 may also extend to overlap with the intermediate layer 1250 asillustrated.

FIG. 12C shows another embodiment where an edge portion of theintermediate layer 1250 is interposed between the IR ink layer 1260 andthe dark ink layer 1270 b. The coupler 1202 is attached to the exteriorframe zone. The dark ink layer 1270 a is applied to cover the remainingbottom surface of the IR ink layer 1260 that is not covered by thecoupler 1202. In the example shown in FIG. 12C, the dark ink layer 1270b abuts the coupler 1202, extending inwards to cover exactly the samearea as the IR ink layer 1260. In other cases, the dark ink layer maycover different areas from the IR ink layer.

FIG. 13 is a side view of an optical touch-sensitive device illustratinga frame made with an IR black optical coupler and a dark ink layer. Inthis embodiment, the IR black coupler 1362 is made of poly(methylmethacrylate) (PMMA), or a similar material such as polycarbonate (PC).Such materials are transparent to IR light but absorb visible light.

In FIG. 13, the IR black coupler 1362 is shown to include an extensionwing 1364 that extends to the outer edge of the bottom surface of thewaveguide 1304. The extension wing 1364 extends the coupling surface1330, acting as the exterior frame zone. In addition to or as analternative to the extension wing 1364, an IR ink layer may be used (notshown). In one implementation, the IR black coupler 1362 is attached tothe waveguide using an adhesive such as OCA (not shown). FIG. 13 alsoshows that the central part of the waveguide 1304 is covered with anintermediate layer 1350 that abuts the IR black coupler 1362. The darkink layer 1370 extends from the IR black coupler 1362 inwards towardsthe display module, overlapping the intermediate layer 1350 and actingas the interior frame zone. The coupler 1362 may include a secondextension wing (not shown) extending inwards towards the display module,which may be used in place of the dark ink layer 1370 or to act as adark background for a partially transparent IR ink layer (not shown).

D. Dead Zones

It is also possible to attach a frame to the top surface of thewaveguide. In one embodiment, such a top frame is constructed byinterposing an intermediate layer between the top surface of thewaveguide and an ink layer. More generally, a top frame may be createdusing the same materials as a bottom frame. While this construction doesnot necessarily have a perfectly flush top surface, a sufficiently thintop frame can be constructed such that the height differential betweenthe top frame and the top surface of the waveguide is not easilyperceived by the user. This is referred to as a near-flush design. Fortop frames, the intermediate layer is also referred to as a cover layer,which may be a low-RI layer or a mirror layer. Top frames cause thewaveguide to be insensitive to touch across their entire extent, and thetop-frame covered zones are referred to as dead zones.

FIG. 14 is a side view of an optical touch-sensitive device illustratingdead zones. In this example, a cover layer 1450 is applied on theperiphery of the top surface of the waveguide 1404. A dark ink layer1470 is then applied on top of the cover layer 1450 to make the deadzones visible to the user. Since light reflection (either TIR orspecular reflection) occurs at the interface between the waveguide 1404and the cover layer 1450, the dark ink layer 1470 does not interact withlight propagating in the waveguide. As shown in FIG. 14, the cover layer1450 does not cover the central part of the touch screen that is used tosense finger presence, although this is not required. Similar dead zonesmay be created along any portion of the display. The visible zoneseparations are not sensitive to touches, and can be used to, forexample, produce a dual display from a single display. In otherimplementations, the dark ink layer 1470 may be omitted, in which casethe dead zones are invisible to the user. In some embodiments, aprotective layer is applied on top of the frame. The protective layermay be transparent or opaque to visible light.

E. Fixed Graphics Zones

In one embodiment, the optical touch-sensitive device includes one ormore touch-sensitive fixed graphics zones, which are attached below thebottom surface of the waveguide. Each fixed graphics zone includes oneor more fixed graphics and one or more associated software buttons.These software buttons typically perform one or more pre-definedsoftware functions with respect to the optical touch-sensitive device inresponse to detection of one or more touches in the vicinity of thefixed graphic zone.

FIG. 15A is a top view of an optical touch-sensitive device illustratinga fixed graphics zone. In FIG. 15A, the display module 1516 occupiesmost of the central portion of the touch sensitive active area, and thefixed graphics zone 1580 is located away from the display module 1516.In this example, the fixed graphics zone 1580 includes four graphics,each associated with a different software button. For example, fixedgraphics zone 1580 illustrates, from left to right, “back”, “menu”,“search”, and “home”, graphics. This example only shows one fixedgraphics zone with four associated fixed buttons, each buttoncorresponding to a different portion of the fixed graphics zone. Inother implementations, the optical touch-sensitive device includesmultiple fixed graphics zones, each zone having one or more fixedbuttons.

FIG. 15B is a side view of an optical touch-sensitive deviceillustrating a fixed graphics zone. The fixed graphics zone includes adark ink layer 1570 and an intermediate layer 1550. The intermediatelayer 1550 is interposed between the dark ink layer 1570 and the bottomsurface of the waveguide. The intermediate layer 1550 prevents lightinteraction with the dark ink layer 1570, and preserves lightpropagation in the waveguide 1504 via TIR or specular reflection. Theintermediate layer is transparent to visible light, so that the portionsof the fixed graphics zone 1580 covered by the dark ink layer 1570 canbe viewed through the top surface of the waveguide. To produce thedesired fixed graphics, the dark ink layer 1570 is patterned as designedfrom a top down perspective. The dark ink layer 1570 may have void areas1572 (i.e., ink-free areas) corresponding to the fixed graphics. Thispartially inked layer may be produced, for example, by using a stencilthat masks dark ink at desired locations. In other cases, the void areasmay instead be filled with a contrast material that appears differentlythan the dark ink to the user.

In an alternative embodiment, the fixed graphics zones are attached onthe top surface of the waveguide as appropriately sized/shaped deadzones (as illustrated in the previous section) while still maintainingtouch sensitivity in the void areas.

F. Logo Zones

In some implementations, the optical touch-sensitive device includes oneor more logo zones, which are attached below the bottom surface of thewaveguide. Each logo zone includes one or more logos, which areprotected from wear and damage by virtue of being placed on thewaveguide's bottom surface (i.e., away from touch interactions). Sincelogos are often printed in color (e.g., silver), a reflective ink layer(e.g., a reflective silver ink layer or other reflective materials) canbe used which contains the desired logos. The reflective ink layer maybe placed in direct contact with the bottom surface of the waveguide, ina location where the intermediate layer is absent, in place of at leasta portion of the intermediate layer, or between the intermediate layerand the waveguide. If the reflective ink layer is directly in contactwith the waveguide, the reflective ink layer does not materially affectoptical beam propagation in the waveguide. For example, the logos may beplaced in the touch sensitive area or in the exterior frame zone. Otherlayers of material (e.g., an IR ink layer, a dark ink layer, etc.) maybe applied to cover or surround the logos. The logos may be produced ina similar way as the fixed graphics described above.

In one approach, a reflective ink layer containing the desired logos isattached to the bottom surface of the waveguide. An IR ink layer isapplied to the bottom surface of the reflective ink layer including thelogos. A dark ink layer is then applied to the bottom surface of the IRink layer. In another approach, an IR ink layer is first applied to thebottom surface of the waveguide. The IR ink layer includes clear areasfor the logos. A reflective ink layer containing the desired logos isapplied to the bottom surface of the waveguide in the clear areas of theIR ink layer. A dark ink layer is then applied to the bottom surfaces ofthe IR ink layer and the reflective ink layer including the logos.

G. Manufacturing Processes

FIG. 16 illustrates the sequence of steps to manufacture an opticaltouch-sensitive device with a frame using an IR ink layer and a dark inklayer. Such a device may correspond to the one shown in FIG. 12A. Thereare many possible process flows to manufacture such a device, and FIG.16 is only shown as an example.

At step 1610, the device is shown as a bare waveguide that in thisexample embodiment is made of glass 1612. At step 1620, a masking layer1622 is applied to the border of the waveguide, preferably on its bottomsurface. At step 1630, an intermediate layer 1632 (e.g., a low-RI layerwith a thickness of 10-50 microns) is applied to the bottom surface ofthe waveguide. The intermediate layer is shown to cover the central partof the waveguide, and also possibly overlaps with some portion of themasking layer. The low-RI layer may be applied using dip-coating,spin-coating, spray-coating of liquid or vapor deposition of materialssuch as MgF₂ or fluoropolymer/halogenated materials.

At step 1640, the masking layer is removed to reveal bare glass on theborder of the waveguide. At step 1650, an IR ink layer 1652 is appliedto the revealed bare glass on the bottom of the waveguide. At step 1660,a coupler assembly 1662 is attached to the IR ink layer along its inneredge. A layer of OCA may be used to facilitate attaching. At step 1670,a layer of dark ink 1672 is applied inboard of the coupler assembly1662, overlapping the edge portion of the intermediate layer to createan opaque interior frame zone. At step 1680, another layer of dark ink1682 is applied outboard of the coupler assembly 1662, overlapping theIR ink layer to create an opaque exterior frame zone.

FIG. 17 illustrates the sequence of steps to manufacture an opticaltouch-sensitive device with a frame using an IR black optical couplerand a dark ink layer. Such a device may correspond to the one shown inFIG. 13. There are many possible process flows to manufacture such adevice, and FIG. 17 is only shown as an example.

At step 1710, the device is shown as a bare waveguide that in thisexample embodiment is made of glass 1712. At step 1720, an OCA layertogether with a liner layer 1722 is applied to the border of thewaveguide, preferably on its bottom surface. The liner layer functionsas a masking layer for the OCA layer. At step 1730, an intermediatelayer 1732 (e.g., a low-RI layer with a thickness of 10-50 microns) isapplied to the bottom surface of the waveguide. The intermediate layercovers the central part of the waveguide, and also possibly overlapswith some portion of the liner layer. The low-RI layer may be appliedusing dip-coating, spin-coating, spray-coating of liquid or vapordeposition of materials such as MgF₂ or fluoropolymer/halogenatedmaterials.

At step 1740, the liner layer is removed to reveal the OCA layer 1742 onthe border of the waveguide. At step 1750, an IR black coupler assembly1752 is attached to the OCA layer. The IR black coupler assembly hasextension wings that extend to the edges of the waveguide, creating anexterior frame zone. At step 1760, a layer of dark ink 1762 is appliedinboard of the IR black coupler assembly, overlapping the edge portionof the intermediate layer to create an interior frame zone.

V. Applications

The touch-sensitive devices described above can be used in variousapplications. Touch-sensitive displays are one class of application.This includes displays for tablets, laptops, desktops, gaming consoles,smart phones and other types of compute devices. It also includesdisplays for TVs, digital signage, public information, whiteboards,e-readers and other types of good resolution displays. However, they canalso be used on smaller or lower resolution displays: simpler cellphones, user controls (photocopier controls, printer controls, controlof appliances, etc.). These touch-sensitive devices can also be used inapplications other than displays. The “surface” over which the touchesare detected could be a passive element, such as a printed image orsimply some hard surface. This application could be used as a userinterface, similar to a trackball or mouse.

VI. Additional Considerations

The figures depict embodiments of the present invention for purposes ofillustration only. One skilled in the art will readily recognize fromthe following discussion that alternative embodiments of the structuresand methods illustrated herein may be employed without departing fromthe principles of the invention described herein.

Upon reading this disclosure, those of skill in the art will appreciatestill additional alternative structural and functional designs throughthe disclosed principles herein. Thus, while particular embodiments andapplications have been illustrated and described, it is to be understoodthat the disclosed embodiments are not limited to the preciseconstruction and components disclosed herein. Various modifications,changes and variations, which will be apparent to those skilled in theart, may be made in the arrangement, operation and details of the methodand apparatus disclosed herein without departing from the spirit andscope defined in the appended claims.

What is claimed is:
 1. An optical touch-sensitive device for use with adisplay, the touch-sensitive device comprising: a planar opticalwaveguide extending over a surface of the display, the waveguide havinga top surface and a bottom surface; emitters and detectors arrangedalong a periphery of the display; an optical coupler assembly positionedalong the periphery of the display, the optical coupler assemblycoupling optical beams produced by the emitters into the waveguide andout of the waveguide to the detectors, wherein touches on the topsurface of the waveguide disturb the optical beams, the touch-sensitivedevice determining touch events based on the disturbances; and at leastone static dead zone, the static dead zone comprising: a cover layerhaving a top surface and a bottom surface, the bottom surface of thecover layer directly coupled to the top surface of the waveguide, thecover layer preserving optical beam propagation in the waveguide byreflecting optical beams propagating in the waveguide at the coverlayer's bottom surface, wherein the cover layer makes the dead zoneinsensitive to touches; and a dark layer that is opaque to visiblelight, wherein a bottom surface of the dark layer is coupled to the topsurface of the cover layer.
 2. The optical touch-sensitive device ofclaim 1, wherein the cover layer is transparent to visible light.
 3. Theoptical touch-sensitive device of claim 1, wherein the cover layer has athickness greater than at least a penetration depth of an evanescentlight field in the waveguide.
 4. The optical touch-sensitive device ofclaim 1, wherein the cover layer is a low refractive index layer thathas a refractive index smaller than the refractive index of thewaveguide.
 5. The optical touch-sensitive device of claim 4, wherein thethickness of the cover layer is in the range 1 micron to 50 microns. 6.The optical touch-sensitive device of claim 1, wherein the cover layerhas one or more gaps.
 7. The optical touch-sensitive device of claim 1,wherein the waveguide comprises a single plane of material.
 8. Theoptical touch-sensitive device of claim 1, further comprising at leastone fixed graphics zone for displaying fixed graphics, each fixedgraphics zone comprising: an ink layer opaque to visible light, the inklayer comprising the fixed graphics, the optical touch-sensitive deviceperforming pre-defined functions corresponding to touches on the topsurface of the waveguide aimed at the fixed graphics; and an additionalcover layer interposed between the bottom surface of the waveguide andthe ink layer, the additional cover layer of the fixed graphics zonepreserving optical beam propagation in the waveguide and transparent tovisible light.
 9. The optical touch-sensitive device of claim 1, whereinthe optical coupler assembly redirects light rays entering into thewaveguide from an emitter or exiting from the waveguide and entering adetector.
 10. The optical touch-sensitive device of claim 1, furthercomprising a binding layer physically coupling the optical couplerassembly to the waveguide, the binding layer comprising an opticallyclear adhesive that is transparent to optical beams propagating in thewaveguide.
 11. The optical touch-sensitive device of claim 1, whereinthe optical beams have infrared wavelengths ranging from 200 nm to 2000nm.
 12. The optical touch-sensitive device of claim 1, furthercomprising: an intermediate layer interposed between the bottom surfaceof the waveguide and the surface of the display, the intermediate layerpreserving optical beam propagation in the waveguide and beingtransparent to visible light.
 13. The optical touch-sensitive device ofclaim 12, wherein the optical coupler assembly and the waveguide areoptically coupled such that light passes from the optical couplerassembly to the waveguide without interacting with the intermediatelayer.
 14. The optical touch-sensitive device of claim 13, wherein theintermediate layer has a refractive index smaller than a refractiveindex of the waveguide, and optical beam propagation in the waveguide ispreserved via total internal reflection at the bottom surface of thewaveguide.
 15. The optical touch-sensitive device of claim 14, furthercomprising a binding layer physically coupling the intermediate layer tothe display, the binding layer transparent to visible light.
 16. Theoptical touch-sensitive device of claim 14, wherein the intermediatelayer has a thickness greater than at least a penetration depth of anevanescent light field in the waveguide.
 17. The optical touch-sensitivedevice of claim 14, wherein the intermediate layer comprises afluoropolymer material.
 18. The optical touch-sensitive device of claim14, wherein the optical coupler assembly and the waveguide are opticallycoupled such that light passes through the intermediate layer when beingcoupled from the emitters into waveguide and from the waveguide into thedetectors.
 19. The optical touch-sensitive device of claim 14, whereinthe intermediate layer functions as a binding layer physically couplingthe waveguide to the display.
 20. The optical touch-sensitive device ofclaim 12, wherein the intermediate layer is a mirror for the opticalbeams propagating in the waveguide, and optical beam propagation in thewaveguide is preserved via specular reflection at the bottom surface ofthe waveguide.
 21. The optical touch-sensitive device of claim 20,wherein the intermediate layer is a holographic film.
 22. The opticaltouch-sensitive device of claim 20, wherein the intermediate layer is aninterference filter.
 23. The optical touch-sensitive device of claim 12,wherein the optical coupler assembly is transparent to the optical beamspropagating in the waveguide and is opaque to visible light.
 24. Theoptical touch-sensitive device of claim 23, wherein a coupling surfaceof the optical coupler assembly that couples to the waveguide extends toan edge of the bottom surface of the waveguide.
 25. The opticaltouch-sensitive device of claim 23, further comprising a dark ink layerpositioned such that an edge portion of the intermediate layer isinterposed between the dark ink layer and the bottom surface of thewaveguide, the dark ink layer opaque to visible light.
 26. The opticaltouch-sensitive device of claim 12, further comprising an ink layerinterposed between the optical coupler assembly and the waveguide, theink layer transparent to the optical beams propagating in the waveguideand opaque to visible light.
 27. The optical touch-sensitive device ofclaim 26, wherein the ink layer extends to an edge of the bottom surfaceof the waveguide.
 28. The optical touch-sensitive device of claim 26,wherein the ink layer extends to overlap with an edge portion of theintermediate layer.
 29. The optical touch-sensitive device of claim 26,further comprising a dark ink layer positioned such that the ink layerand an edge portion of the intermediate layer are interposed between thedark ink layer and the bottom surface of the waveguide, the dark inklayer opaque to visible light.
 30. The optical touch-sensitive device ofclaim 26, further comprising a dark ink layer positioned such that anedge portion of the intermediate layer is interposed between the inklayer and the dark ink layer and the ink layer is interposed between thebottom surface of the waveguide and the edge portion of the intermediatelayer, the dark ink layer opaque to visible light.
 31. The opticaltouch-sensitive device of claim 12, further comprising a dark layerpositioned such that a bottom surface of the dark layer is directlycoupled to the top surface of the cover layer, the dark layer comprisinga dark material opaque to visible light.
 32. The optical touch-sensitivedevice of claim 31, further comprising a protective layer positionedsuch that a bottom surface of the protective layer is directly coupledto a top surface of the dark layer, the protective layer transparent tovisible light.
 33. The optical touch-sensitive device of claim 12,further comprising: at least one fixed graphics zone for displayingfixed graphics, each fixed graphics zone comprising: an ink layer opaqueto visible light, the ink layer comprising the fixed graphics, theoptical touch-sensitive device performing pre-defined functionscorresponding to touches on the top surface of the waveguide aimed atthe fixed graphics; and an additional intermediate layer interposedbetween the bottom surface of the waveguide and the ink layer, theadditional intermediate layer of the fixed graphics zone preservingoptical beam propagation in the waveguide and transparent to visiblelight.
 34. The optical touch-sensitive device of claim 12, furthercomprising: at least one frame zone, each frame zone comprising: an inklayer opaque to visible light; and an additional intermediate layerinterposed between the bottom surface of the waveguide and the inklayer, the additional intermediate layer of the frame zone preservingoptical beam propagation in the waveguide and transparent to visiblelight.
 35. The optical touch-sensitive device of claim 12, wherein theoptical coupler assembly is a multi-part assembly, a first part of theoptical coupler assembly is positioned underneath the bottom surface ofthe waveguide within and surrounded by the intermediate layer and asecond part of the optical coupler assembly is positioned underneath theintermediate layer.
 36. The optical touch-sensitive device of claim 35,wherein the optical coupler assembly has a refractive index that isclose to or substantially matched with a refractive index of theintermediate layer.
 37. The optical touch-sensitive device of claim 1,wherein the cover layer is a low-RI layer.
 38. The opticaltouch-sensitive device of claim 1, wherein the cover layer is applied tothe waveguide using a lamination process.
 39. The opticaltouch-sensitive device of claim 1, wherein the cover layer is a mirrorlayer.
 40. The optical touch-sensitive device of claim 1, wherein the atleast one static dead zone further comprises: a protective layer that istransparent to visible light, wherein a bottom surface of the protectivelayer is coupled to a top surface of the dark layer.